Method of forming fiber-resin mold products wherein the resin is an intermediate stage thermosetting resin

Claim 1

IN THE METHOD OF PRODUCING A MOLDABLE PULP-RESIN PRODUCT WHEREIN THE RESIN IS CAPABLE OF ADVANCEMENT TO A CURED STAGE DURING MOLDING CONSISTING OF THE STEPS OF DISPERSING THE PULP FIBERS IN AN AQUEOUS SYSTEM UNIFORMLY TO DISTRIBUTE THE PULP FIBERS AND OPEN THE PULP FOR RECEIPT OF THE RESINOUS MATERIAL, INTRODUCING A THERMOSETTING RESINOUS MATERIAL IN AN INTERMEDIATE STAGE OF POLYMERIC GROWTH AND IN A WATER SOLUBLE STATE FOR SOLUTION IN THE AQUEOUS MATERIAL WITHOUT NOTICEABLE INCREASE IN VISCOSITY AND ADHESIVENESS OF THE RESULTING AQUEOUS SYSTEM, AND THEN DRYINH THE MIXTURE AT A TEMPERATURE BELOW 200*F. TO A CRUMBLY, FLOCCULENT MASS OF PULP FIBERS WITHOUT ADVANCEMENT OF THE RESINOUS MATERIAL BEYOND AN INTERMEDIATE STAGE OF POLYMERIC GROWTH WITH THE RESIN UNIFORMLY DISTRIBUTED THEREIN AND IN WHICH THE RESINOUS MATERIAL IS INTRODUCED IN AN AMOUNT WITHIN THE RANGE OF 3 PARTS BY WEIGHT OF RESON TO 97 PARTS BY WEIGHT OF PULP FIBERS AS A MINIMUM TO 60 PARTS BY WEIGHT OF RESIN AND 40 PARTS BY WEIGHT OF PULP FIBERS AS A MAXIMUM.